Mobile apparatus with local position referencing structure

ABSTRACT

A position-referenced mobile system includes: a mobile apparatus including: a transport mechanism for moving the mobile apparatus along or substantially along a plane of motion; a rotatable position detection assembly including: a laser; a first photo detector; and a second photo detector; and at least one encoder for monitoring an amount of rotation of the position detection assembly; a controller for interpreting signals provided by the first photo detector and the second photo detector; and a position referencing structure including: a reflective linear reference member; a first reflective cylindrical surface disposed at a first end of the linear reference member; and a second reflective cylindrical surface disposed at a second end of the linear reference member.

CROSS REFERENCE TO RELATED APPLICATIONS

Reference is made to commonly assigned, co-pending U.S. patentapplication Ser. No. K001392, concurrently filed herewith, entitled“Determining a Position of a Mobile Apparatus” by Greg Burke et al; andco-pending U.S. patent application Ser. No. ______ (K001353),concurrently filed herewith, entitled “Mobile Apparatus with LocalPosition Referencing Elements” by Greg Burke; and co-pending U.S. patentapplication Ser. No. ______ (K001391), concurrently filed herewith,entitled “Method of Positioning a Mobile Apparatus” by Greg Burke, thedisclosures of which are herein incorporated by reference.

FIELD OF THE INVENTION

This invention relates generally to the field of motion-controlledmobile units, and more particularly to a mobile apparatus whose motionis controlled with reference to a local position referencing structure.

BACKGROUND OF THE INVENTION

A mobile apparatus can be controlled to perform an operation as afunction of a position of the mobile apparatus. Such operations caninclude modifying a surface over which the mobile apparatus is moved,ejecting a liquid onto a medium, printing an image, fabricating adevice, or cutting a surface, for example. The accuracy to which theposition of the mobile apparatus must be known depends upon theoperation to be performed and the quality of the resulting output thatis required. For example, the print quality of a sign that is to beviewed at a long distance does not require as high a degree ofpositional accuracy of printing as does a poster-sized print of aphotographic image. In addition, the placement of different portions ofan image that are separated by white space is not as critical of theplacement of different portions of an image that are adjacent to eachother and printed on separate printing swaths.

U.S. Pat. No. 6,116,707 discloses a robotic plotting system in which aprinthead is placed on a substantially flat horizontal surface uponwhich a recording medium is placed. The robotic plotter printhead isdirected across the medium by infrared, ultrasound or microwave signalsthat are transmitted to the printhead from the periphery of therecording medium. The printhead includes a motorized drive mechanismthat propels it across the surface of the recording medium using controlsignals. U.S. Pat. No. 6,951,375 discloses a wheeled vehicle thatincludes motors, encoders, and an inkjet printhead for printing on alarge surface area or walkway.

What is needed is a simple, reliable and accurate way of determining theposition of a mobile apparatus for performing an operation, such asprinting, as a function of the position of the mobile apparatus. It isalso advantageous for positioning reference structure to include abuilt-in distance measurement reference.

SUMMARY OF THE INVENTION

A position-referenced mobile system comprises: a mobile apparatusincluding: a transport mechanism for moving the mobile apparatus alongor substantially along a plane of motion; a rotatable position detectionassembly including: a laser; a first photo detector; and a second photodetector; and at least one encoder for monitoring an amount of rotationof the position detection assembly; a controller for interpretingsignals provided by the first photo detector and the second photodetector; and a position referencing structure including: a reflectivelinear reference member; a first reflective cylindrical surface disposedat a first end of the linear reference member; and a second reflectivecylindrical surface disposed at a second end of the linear referencemember.

BRIEF DESCRIPTION OF THE DRAWINGS

In the detailed description of the preferred embodiments of theinvention presented below, reference is made to the accompanyingdrawings, in which:

FIG. 1 schematically shows a position-referenced mobile system accordingto an embodiment of the invention;

FIG. 2 schematically shows a rotary encoder;

FIG. 3 is an end view showing a configuration of a laser and hollowtubes for a first photo detector and a second photo detector accordingto an embodiment of the invention;

FIG. 4 shows a side view of a portion of the position-referenced mobilesystem of FIG. 1;

FIG. 5 illustrates signal amplitudes received by the first and secondphoto detectors as a function of rotation angle;

FIG. 6 is a schematic top view of a position referencing structure andillustrates how position of the mobile apparatus can be determined;

FIG. 7 illustrates how a new heading of the mobile apparatus can be setwith reference to a linear reference member;

FIG. 8 shows an embodiment of a linear reference member with referencemarkings;

FIG. 9 shows an embodiment of a linear reference member with a shadinggradient;

FIG. 10 schematically shows a position-referenced mobile systemaccording to another embodiment of the invention;

FIG. 11 shows an embodiment of a linear reference member having a curvedsurface;

FIG. 12 shows an embodiment of a positioning referencing structure madeof parts that are assembled together; and

FIG. 13 shows a bottom view of the mobile apparatus including anoperating device for performing an operation as a function of positionof the mobile apparatus.

DETAILED DESCRIPTION OF THE INVENTION

The present description will be directed in particular to elementsforming part of, or cooperating more directly with, apparatus inaccordance with the present invention. It is to be understood thatelements not specifically shown or described may take various forms wellknown to those skilled in the art.

FIG. 1 schematically shows a position-referenced mobile system 200including a mobile apparatus 140, a controller 170 and a positionreferencing structure 210 according to an embodiment of the presentinvention. The mobile apparatus 140 is located within a positiondetection region 110, which can include a sheet of medium 115 lying flaton a horizontal table or floor, for example. The support surface, suchas a horizontal table or floor, or the sheet of medium 115 that lies onthe support surface, determines a plane of motion 117 of the mobileapparatus 140. It is noted that FIG. 1 is not to scale. The mobileapparatus 140 is shown artificially large compared to a positiondetection region 110 so that details of the mobile apparatus 140 can beseen more clearly. A typical length of the mobile apparatus 140 can bearound several inches, while a typical length and width of the positiondetection region 110 can be around several feet.

The mobile apparatus 140 includes a chassis 143 having a first edge 141and a second edge 142 that is opposite the first edge 141. A transportmechanism 150 for moving the mobile apparatus 140 along or substantiallyalong the plane of motion 117 includes a first wheel 151 rotatablymounted near the first edge 141 and a second wheel 152 is rotatablymounted near the second edge 142. A first motor 155 provides power torotate the first wheel 151 about a hub 154. A second motor 155 (notvisible in FIG. 1) provides power to rotate the second wheel 152independently of the first wheel 151. Both the first wheel 151 and thesecond wheel 152 can be independently driven by their respective motors155 in a first rotational direction 145 (forward) or in a secondrotational direction (reverse) opposite the first rotational direction145. Driving the first wheel 151 in the first rotational direction 145while also driving the second wheel 152 in the first rotationaldirection causes the mobile apparatus 140 to move from one location to adifferent location. The first wheel 151 is driven in the firstrotational direction 145, while driving the second wheel 152 in thesecond rotational direction that is opposite the first rotationaldirection 145 causes the mobile apparatus 140 to rotate to a differentorientation. At least one freely rotating ball or caster 153 helps tothe support chassis 143 and is able to turn in any direction as requiredby movement of the driven first and second wheels 151 and 152. Forimproved motion control, it is preferable that the freely rotating ball153 trails the first and second wheels 151 and 152 as they move themobile apparatus 140. The trailing, freely rotating ball or caster 153is shown in FIG. 1 as being near the first edge 141. There can also beanother trailing freely rotating ball 153 (not shown) near the secondedge 142. Rather than freely rotating balls or casters, the support canbe provided by freely swiveling wheels (not shown). In otherembodiments, the freely rotating ball or freely swiveling wheel (notshown) can be more centrally positioned between the first edge 141 andthe second edge 142. In other embodiments (not shown) the transportmechanism can include independently driven motorized continuous tracksanalogous to the continuous tracks used on bulldozers.

A first rotary encoder 157 (FIG. 2) is mounted on a shaft 156 of firstmotor 155 in order to monitor an amount of rotation of first motor 155and first wheel 151. Rotary encoder 157 typically includes a pluralityof radial lines 158 (FIG. 2) disposed around the circumference of adisk. An optical sensor (not shown) detects rotation of the disk by highsignals corresponding to light passing through transparent regions ofthe disk or low signals corresponding to light being blocked by theradial lines 158. For simplicity in FIG. 2, the radial lines 158 areshown as being spaced about every 22.5 degrees. In actual rotaryencoders, the radial lines 158 are typically spaced about every degree.The rotary encoder 157 typically includes a detectable referenceposition 159. In the configuration shown in FIG. 2, the detectablereference position 159 is shown as an elongated radial line 158. Asecond rotary encoder 157 is mounted on a shaft of the second motor (notvisible in FIG. 1) to monitor an amount of rotation of the second motorand the second wheel 152. Monitoring the first and second rotaryencoders 157 while driving the first wheel 151 and the second wheel 152in the same rotational direction (and knowing the diameters of thewheels), allows the calculation of a distance moved by the mobileapparatus 140. Monitoring the first and second rotary encoders 157 whiledriving the first wheel 151 and the second wheel 152 in oppositerotational directions (and knowing a distance between the wheels)permits the calculation of an amount of rotation by the mobile apparatus140.

A rotatable position detection assembly 260 includes a first photodetector 261, a second photo detector 263 and a laser 265. In theconfiguration shown in FIG. 1, the first photo detector 261 is disposedwithin a first hollow tube 262, the second photo detector 263 isdisposed within a second hollow tube 264, and the laser 265 is disposedwithin a cylindrical package 266. It is not required that the laser 265have a cylindrical package 266, but such a package shape can be helpfulin aligning the laser 265 such that its beam is emitted substantiallyparallel to the first hollow tube 262 and the second hollow tube 264.Also in the configuration shown in FIG. 1 and the schematic side view ofFIG. 4, the first photo detector 261, the second photo detector 263 andthe laser 265 are mounted on a turret 250 having a rotational axis 251that is perpendicular to or substantially perpendicular to the plane ofmotion 117 of the mobile apparatus 140. A turret motor 255 (FIG. 4)rotates the turret 250 in a rotational direction 252 about a rotationalaxis 251. A rotary encoder 257 (similar to rotary encoder 157 describedabove with reference to FIG. 2) is mounted on a shaft 256 of the turret255 (or alternatively on a shaft 254 of the turret motor 255 formonitoring an amount of rotation θ of the position detection assembly260. A gear 258 associated with the shaft 254 of the turret motor 255engages with a gear 259 associated with the shaft 256 of the turret 255to provide rotational power for the turret 250. In other embodimentswhere there is no turret 250, the rotatable mobile apparatus 140 itselfcan function as a part of the rotatable position detection assembly 260for orienting the first and second photo detectors 261 and 263 and thelaser 265 in different directions. However, configurations having theturret 250 are advantaged in that it is not required to rotate theentire mobile apparatus 140 and are less susceptible to errors due towheel slippage.

The first hollow tube 262, the second hollow tube 264 and the laser 265are aligned parallel to one another and are closely positioned relativeto one another. An advantageous configuration is schematically shown inthe end view of FIG. 3 where a first axis 242 of the first hollow tube262, the second axis 244 of the second hollow tube 264, and a third axis245 of the laser 265 are arranged in a triangular relationship relativeto each other. In particular the first axis 242 and the second axis 244are disposed within a detection plane 217 that is parallel to orsubstantially parallel to the plane of motion 117 (FIG. 1), such thatthe third axis 245 of the laser 265 is disposed between the first axis242 and the second axis 244 and is displaced from the detection plane217. If the first and second hollow tubes 262, 264 and the laser 265 areaimed toward the positioning referencing structure 210 (FIG. 1), anincident beam 267 emitted from the laser 265 can be reflected from aportion of a surface of the position referencing structure 210 that issubstantially perpendicular to the incident beam 267 such that it can bereceived as the first reflected beam 268 by the first photo detector 261or as the second reflected beam 269 by the second photo detector 263.The first and second hollow tubes 262 and 264 are opaque in order toreduce the amount of stray light impinging on the first and second photodetectors 261 and 263 so that primarily the light received by the firstand second photo detectors 261 and 263 is light from laser 265 that isreflected from a reflective surface such as the first and secondreflective cylindrical surfaces 221 and 222. A typical diameter of thefirst and second hollow tubes 262 and 264 and of the incident beam 267emitted from the laser 265 is about 3 millimeters. In the schematic viewof FIG. 1, the first and second hollow tubes 262 and 264 and thecylindrical package 266 are shown as transparent so that the first andsecond photo detectors 261 and 263 and the laser 265 can be indicated.The controller 170, which in the embodiment shown in FIG. 1 is mountedon the mobile apparatus 140, interprets electrical signals provided bythe first and second photo detectors 261 and 263 and makes calculationsto determine position of the mobile apparatus 140. The controller 170also interprets signals from the rotary encoders 157 for the first andsecond wheels 151 and 152 as well as the turret 250, sends signals forthe motors 155 and 255 for moving or rotating the mobile apparatus 140and the turret 250, and provides overall control of the operation ofmobile apparatus 140. A power source 175 is also mounted on the mobileapparatus 140 and provides power for the motors 155 and 255, thecontroller 170, the laser 265, and other devices associated with theoperation of the mobile apparatus 140.

In the configuration shown in FIG. 1, the position referencing structure210 is shown as being positioned near to but outside of the positiondetection region 110. The position detection region 110 can also becalled a work space since it corresponds to a region in which mobileapparatus 140 (FIG. 1) can move and operate as a function of itsposition. The position referencing structure 210 includes a reflectivelinear reference member 230, a first reflective cylindrical surface 221disposed at a first end 231 of linear reference member 230, and a secondreflective cylindrical surface 222 disposed at a second end 232 of thelinear reference member 230. An axis 224 of the first reflectivecylindrical surface 221 is located at a predetermined distance D₁ froman axis 225 of a second reflective cylindrical surface 222. The axis 224and the axis 225 are perpendicular or substantially perpendicular to theplane of motion 117. The linear reference member 230 and first andsecond reflective cylindrical surfaces 221 and 222 are observable by thefirst and second photo detectors 261 and 263 when the mobile apparatus140 is located within the position detection region 110. However, astrong light signal will only be detected by the first photo detector261 or the second photo detector 263 when the laser 265 is pointedtoward the axis 224 of the first cylindrical surface 221, toward theaxis 225 of the second reflective cylindrical surface 222, orperpendicularly toward the linear reference member 230. FIG. 4schematically illustrates the incident beam 267 from the laser 265 beingreflected as the first reflected beam 268 into the first hollow tube 262from the linear reference member 230 (FIG. 1). Optionally, a colorfilter (not shown) can be included in front of the first and secondphoto detectors 261 and 263 in order to filter out wavelengths that donot correspond to the laser 265. A property of a reflective cylindricalsurface is that as the orientation of the first and second hollow tubes262 and 264 and the laser 265 changes, for example, as the turret 250 isrotated, a strong light signal will be detected by the first photodetector 261 or the second photo detector 264 over a very small range ofangles where the incident beam 267 and the first reflected beam 268 aresubstantially perpendicular to the cylindrical surface such as first andsecond reflective cylindrical surfaces 221 and 222.

A method of identifying an orientation corresponding to perpendicularityof the laser 265 to a portion of the positioning reference structure 210is illustrated in FIG. 5, which shows an signal amplitude 271 detectedby the first photo detector 261 and a signal amplitude 272 detected bythe second photo detector 263 as a function of rotation angle θ of theturret 250 (FIGS. 1 and 4). The signal amplitude 271 has a peak 273 atangle θ₁ and the signal amplitude 272 has a peak 274 at angle θ₂. Thepeaks 273 and 274 are detected at different angles because the firstphoto detector 261 and the second photo detector 263 are displaced fromone another. With reference also to FIG. 3, since a third axis 245 ofthe laser 265 is midway between the first axis 242 of the first hollowtube 262 and the second axis 244 of the second hollow tube 264, theturret angle θ_(P) corresponding to the third axis 245 of the laser 265being perpendicular to the portion of the position referencing structure210 (FIG. 1) is midway between θ₁ and θ₂. In particular, by comparing asignal from the first photo detector 261 to a signal from the secondphoto detector 263 as a function of the amount of rotation, θ_(P) can beidentified as the orientation such that further rotation of the turret250 in a first direction 275 causes the signal amplitude 271 from thefirst photo detector 261 to increase and the signal amplitude 272 fromthe second photo detector 263 to decrease. Similarly at turret angleθ_(P), further rotation of the turret 250 in a direction opposite thefirst direction 275 causes the signal amplitude 271 from the first photodetector 261 to decrease and the signal amplitude 272 from the secondphoto detector 263 to increase. Actual signal amplitude data willinclude a number of noise peaks (not shown) that are significantlysmaller in amplitude than the peaks 273 and 274. In order to avoidincorrectly identifying Op due to noise peaks, a predetermined threshold276 can be defined. The orientation corresponding to perpendicularity ofthe laser 265 to a portion of the position reference structure 210 caninclude verifying that the signal amplitudes 271 and 272 at the peaks273 and 274 respectively are at least as large as the predeterminedthreshold 276.

FIG. 6 is a schematic top view of the position referencing structure 210and illustrates how (X,Y) coordinates of a position P of the mobileapparatus 140 (FIG. 1) can be determined. A first vector 281 fromposition P to the axis of the first reflective cylindrical surface 221indicates a first orientation corresponding to perpendicularity of thelaser 265 to the first reflective cylindrical surface 221. A secondvector 282 from position P to the linear reference member 230 indicatesa second orientation corresponding to perpendicularity of the laser 265to the linear reference member 230. A third vector 283 from position Pto the axis of the second reflective cylindrical surface 222 indicates athird orientation corresponding to perpendicularity of the laser 265 tothe second reflective cylindrical surface 222. Define an XY coordinatesystem such that axis 224 of first cylindrical surface 221 is at theorigin and linear reference member 230 is along the X axis. Then, sincethe distance between the axis 224 of the first reflective cylindricalsurface 221 and the axis 225 of the second reflective cylindricalsurface 222 is D₁, the coordinates of the axis 224 and the axis 225 are(0,0) and (D₁,0) respectively. Since the second vector 282 isperpendicular to the linear reference member 230 it is parallel to the Yaxis. Let h be the distance between position P to the linear referencemember 230 and let the second vector 282 intersect the linear referencemember 230 a distance d from axis 224 of the first reflectivecylindrical surface 221. Then in the configuration shown in FIG. 6, thecoordinates of P are (d, −h). The Y coordinate of P is negative in thisexample since P is below the X axis. Angle α is measured using rotaryencoder 257 (FIG. 4) to measure the difference in orientations of theturret 250 between the strong reflection corresponding to theperpendicular to first reflective cylindrical surface 221 and the strongreflection corresponding to the perpendicular to the linear referencemember 230. Similarly angle β is the difference in orientations of theturret 250 between the strong reflection corresponding to theperpendicular to the linear reference member 230 and the strongreflection corresponding to the perpendicular to the second reflectivecylindrical surface 222. Then by trigonometry,

d=h/tan α=h cot α  (1) and

D ₁ −d=h/tan β=h cot β  (2), so that

D ₁ =h(cot α+cot β)  (3), so that

h=D ₁/(cot α+cot β)  (4) and

d=D ₁ cot α/(cot α+cot β)  (5).

In other words, the (X,Y) coordinates of position P of the mobileapparatus 140 are determined by firing the laser 265 that is mounted onthe mobile apparatus 140; rotating as a unit, the laser 265 and thefirst and second photo detectors 261 and 263 located near the laser 265(for example by rotating the turret 250) while monitoring an amount ofrotation using the rotary encoder 257; detecting and analyzing the firstsignal amplitude 271 of light received by the first photo detector 261and the second signal amplitude 272 of light received by the secondphoto detector 263 as a function of the amount of rotation θ;identifying a first orientation (first vector 281) corresponding toperpendicularity of the laser 265 to the position reference structure210 (in particular to the first reflective cylindrical surface 221);identifying a second orientation (the second vector 282) correspondingto perpendicularity of the laser 265 to the position reference structure210 (in particular to linear reference member 230); identifying a thirdorientation (the third vector 283) corresponding to perpendicularity ofthe laser 265 to the position reference structure 210 (in particular tothe second cylindrical surface 222); and calculating the positioncoordinates for position P of mobile apparatus 140 based on the firstorientation, the second orientation, the third orientation and apredetermined distance D₁ that is associated with the position referencestructure 210. The steps of identifying orientations and calculatingposition coordinates are done using the controller 170 (FIG. 1).

After position P has been calculated, the mobile apparatus 140 can bemoved to a second location while the distance moved from calculatedposition P to the second location is monitored, for example using therotary encoders 157 (FIG. 2) to measure how much a wheel (typically boththe first wheel 151 and second wheel 152) of known diameter has rotated.It is typically important not only to monitor the distance moved by themobile apparatus 140, but also to move along a desired heading. As shownschematically in the top view of FIG. 7, a new heading H can be set withreference to the linear reference member 230. Once the orientation ofthe turret 250 corresponding to perpendicularity of the laser 265 andthe first and second photo detectors 261 and 263 to the linear referencemember 230 (i.e. the second vector 282) has been determined, the motors155 (FIG. 1) for the first wheel 151 and the second wheel 152 can beservo-controlled using the controller 170 to preserve perpendicularityto the linear reference member 230 by monitoring the signal amplitude271 and the signal amplitude 272 (FIG. 5) during further motion. Then ifthe controller 170 instructs the turret motor 255 to turn the turret 250by a desired angle γ relative to the second vector 282 corresponding tothe change in heading while monitoring rotation using the rotary encoder257 (FIG. 4), the servo-controlled motors 155 will adjust rotation ofthe first wheel 151 and the second wheel 152 to preserveperpendicularity of the laser 265 and the first and second photodetectors 261 and 263 to the linear reference member 230. As a result,mobile apparatus 140 will reorient itself along the desired heading H.Continued forward movement of the mobile apparatus 140 will be along thedesired heading H by preserving perpendicularity of the laser 265 andthe first and second photo detectors 261 and 263 to the linear referencemember 230 as mobile apparatus 140 moves. By measuring distance traveledusing the rotary encoders 157 along heading H while monitoring signalsfrom the first and second photo detector 261 and 263 to preservestraight line motion along heading H, a position of the new location canbe calculated.

Improvements in the accuracy, reliability or speed of calculating newlocation positions or headings are provided in other embodiments. Asdescribed above with reference to FIG. 6, after position P has beencalculated, the mobile apparatus 140 can be moved to a second locationwhile the distance moved from calculated position P to the secondlocation is monitored, for example using rotary encoders 157 (FIG. 2) tomeasure how much a wheel (typically both first wheel 151 and secondwheel 152) of known diameter has rotated. In some instances, slippage ofthe first and second wheels 151 and 152 can introduce errors into thecalculation of the new position. FIG. 8 shows the position referencestructure 210 such that the linear reference member 230 includes aplurality of reference markings 233. A set of first reference markings234 have a different width than a width of a set of second referencemarkings 235 and are regularly interspersed. In the example of FIG. 8,every fifth reference marking 233 is a first reference marking 234 witha wider width than the width of the second reference markings 235. Inthis way, the controller 170 (FIG. 1) can do a check of its calculatedposition according to the absolute reference markings 233 provided onthe linear reference member 230. Reference markings are spaced apart bya spacing s that is larger than a width of a beam from the laser 265. Inthis way, the reference markings 233 can be well resolved. Thecontroller 170 can interpret the signal amplitudes 271 and 272 (FIG. 5)to tell the difference between a reference marking 233 and a conditionof perpendicularity in the following way. As described above withreference to FIG. 5, a condition of perpendicularity to the linearreference member 230 corresponds to an orientation where furtherrotation in one direction causes the signal amplitude 271 to increasewhile the signal amplitude 272 decreases, and vice versa for rotation inthe opposite direction. By contrast, as a reference marking 233 comesinto view of the first photo detector 261 and then the second photodetector 263, the signal amplitude 271 will decrease and then the signalamplitude 272 will also decrease. The extent of the decrease as afunction of rotation will depend on the width of the reference marking233.

FIG. 9 shows the linear reference member 230 where the referencemarkings 233 include a periodic shading gradient 236 along the length ofthe linear reference member 230. A periodic shading gradient 236 canprovide a more precise indication of location in analog fashion than theline-style reference markings 233 of FIG. 8.

FIG. 10 schematically shows the position referencing structure 210 wherethe linear reference member 230 is a first linear reference member, andthere is a second linear reference member 237 that is alignedperpendicular or substantially perpendicular to the first linearreference member 230. The second linear reference member 237 has a firstend 238 that is near first reflective cylindrical surface 221 and asecond end 239 opposite first end 238. A third reflective cylindricalsurface 223 is located at second end 239 of second linear referencemember 237. The axis 224 of first reflective cylindrical surface 221 isdisposed at a predetermined distance D2 from axis 229 of thirdreflective cylindrical surface 223. In the example shown in FIG. 10 boththe first linear reference member 230 and the second linear referencemember 237 include a plurality of reference markings 233. In addition,in this example where the laser 265 is a first laser, there is a secondlaser 295, a third photo detector 291 and a fourth photo detector 293that are packaged and configured similarly to the first laser 265, thefirst photo detector 261 and second photo detector 263 respectively. Inaddition, the first laser 265 and the second laser 295 are orientedperpendicular or substantially perpendicular to each other. The secondlaser 295 emits a second incident beam 297. Third reflected beam 298 isreceived by the third photo detector 291. A fourth reflected beam 299 isreceived by the fourth photo detector 293. By detecting orientations ofstrong reflections from the second laser 295 from the second linearreference member 237, the first reflective cylindrical surface 221 andthe third reflective cylindrical surface 223 as a function of angle in asimilar fashion to that described above relative to FIG. 6, a secondmeasurement of position coordinates of the mobile apparatus 140 iscalculated to provide greater measurement reliability. In particular, afourth orientation corresponding to perpendicularity of the second laser295 to the position referencing structure 210 (in particular to firstreflective cylindrical surface 221), a fifth orientation correspondingto perpendicularity of the second laser 295 to the position referencingstructure 210 (in particular to second linear reference member 237), anda sixth orientation corresponding to perpendicularity of the secondlaser 295 to the position referencing structure 210 (in particular tothird reflective cylindrical surface 223) are identified and used alongwith second predetermined distance D₂ to recalculate the position ofmobile apparatus 140.

An advantage of providing the additional check of the positioncoordinates by adding the second linear reference member 237 and thethird reflective cylindrical surface 223 is that the accuracy of thesystem is improved when the mobile apparatus 140 is at greater distancesfrom position referencing structure 210. For the position referencingstructures 210 arrayed along a single direction (as in FIG. 1), there isa region adjacent and parallel to the linear reference member 230 thatis a few inches wide where the accuracy of position calculation is lessaccurate. For the positioning referencing structures 210 arrayed alongtwo directions (as in FIG. 10), the region of less accuracy is confinedto a smaller region within a few inches of the first reflectivecylindrical surface 221. In addition, a position referencing structurehaving reference markings arrayed along two directions (FIG. 10)provides XY data to the mobile apparatus 140 as it moves in anydirection. The positioning reference structure 210 having referencemarkings along a single direction (FIGS. 7-8) provides position data tomobile apparatus 140 in a single direction.

Some embodiments include the position referencing system 210 arrayedalong two directions (as in FIG. 10), but only have the laser 265, thefirst photo detector 261 and the second photo detector 263 on the mobileapparatus 140. In such embodiments a first calculation is based onorientations of strong reflection of the laser 265 from the firstreflective cylindrical surface 221, the first linear reference member230 and the second reflective cylindrical surface 222 to determineposition of the mobile apparatus 140. The position calculation can bechecked using orientations of strong reflections of the laser 265 fromthe first reflective cylindrical surface 221 (again), the second linearreference member 237 and the third reflective cylindrical surface 223.

Still other embodiments provide a linear reference member 285 having acurved surface 286 having an axis 287 that is parallel or substantiallyparallel to the XY plane of motion 117 as shown in FIG. 11. As a result,when the laser 265 emits the incident beam 267 so that it reflects offthe curved surface 286, the reflected beam 288 is elongated into anarrow line along the Z direction. The reflected beam 288 is stillnarrow for accurate orientation detection as a function of rotationangle θ in the XY plane. The elongation of the reflected beam 288 in theZ direction facilitates horizontal alignment of the laser 265 and thefirst and second photo detectors 261 and 263 as compared to the linearreference member 230 having a flat reflecting surface, especially if theflat reflecting surface is not quite perpendicular to the XY plane ofmotion 117.

In some embodiments, the position referencing structure 210 is formed asa single unit, for example by injection molding and metal coating thesurfaces to make them reflective. In other embodiments, such as theconfiguration shown in the top view of FIG. 12, the first reflectivecylindrical surface 221 is part of the first cylinder 226, and thesecond reflective cylindrical surface 222 is part of a second cylinder227. The first cylinder 226 and second cylinder 227 are positionedrespectively at the first end 231 and the second end 232 of linearreference member 230. In such embodiments it can be advantageous toprovide alignment features 228 at the first end 231 and the second end232 for accurately positioning the first cylinder 226 and the secondcylinder 227.

A bottom schematic view of a portion of mobile apparatus 140 is shown inFIG. 13. The first wheel 151 and the second wheel 152 are shown withtheir respective wheel gears 168. The first motor 155 drives the firstwheel 151 via a motor gear 167 that engages wheel gear 168. The rotaryencoder 157 on the shaft 156 monitors the amount of wheel rotation bymeasuring the amount of motor rotation. Similarly, the second motor 155drives the second wheel 152 via a motor gear 167 that engages wheel gear168. The rotary encoder 157 on the shaft 156 monitors the amount ofwheel rotation by measuring the amount of motor rotation. The first andsecond wheels 151 and 152 can therefore be driven and monitoredindependently of each other. Also shown in FIG. 13 is an operatingdevice 180 for performing an operation directed by the controller 170(FIG. 1) as a function of detected position of the mobile apparatus 140.In the example shown in FIG. 13, the operating device 180 includes amarking device. In particular, the marking device is a printhead 182having a printhead die 184 containing an array of nozzles 186 forejecting drops of liquid. The drops of liquid can include colored inks,such that ejecting at least one drop of liquid as a function of locationof the mobile apparatus 140 includes printing a portion of an image on asheet of medium 115 (FIG. 1) with which the first and second wheels 151and 152 are in contact. Alternatively the drops of liquid can includesolutions including conductive particles, resistive particles,insulating particles, semiconducting particles or magnetic particles forfunctional printing as a function of location of the mobile apparatus140 in order to fabricate a device or a circuit according to controlsignals by controller 170 (FIG. 1). More generally performing anoperation by the operating device 180 includes modifying a surface (suchas a surface of sheet of medium 115) over which the mobile apparatus 140is moved. Modifying the surface can include marking the surface,depositing liquid drops on the surface (as described above),illuminating the surface, heating the surface, or cutting the surfacefor example. Alternative types of the operating devices 180 (in additionto a printhead 182 for depositing liquid drops) include a laser forillumination or heating, or a blade for cutting the surface. Also shownin FIG. 13 is at least one photosensor array 190 for detecting an edgeof sheet of the medium 115 in order to properly position the surfacemodification relative to sheet of medium 115. The photosensor array 190can also provide feedback about previously modified or marked regions ofsheet of the medium 115.

A method of performing an operation by the operating device 180 on themobile apparatus 140 as a function of position of the mobile apparatushas been provided. The method includes determining successive positionsof the mobile apparatus 140 as described above with reference to FIGS. 1to 11. In particular, a position of a first location of the mobileapparatus 140 is calculated with reference to the position referencingstructure 210. A signal is then sent from the controller 170 to theoperating device 180 to perform an operation. Then the mobile apparatus140 is moved away from the first location to a second location. Theposition of the second location is calculated. A signal is sent from thecontroller 170 to the operating device 180 to perform an operationcorresponding to the second location. The process of moving to a newlocation and performing an operation corresponding to that location istypically repeated many times to complete a task such as printing animage on a sheet of the medium 115.

In some embodiments it is desired to avoid having the first and secondwheels 151 and 152 or balls 153 run over a region where the surface hasbeen modified. For example, a functional device that is fabricated byejecting drops of solutions including conductive particles, resistiveparticles, insulating particles, semiconducting particles or magneticparticles can potentially be degraded if it is subsequently run over.For functional devices having a width that is less than the distancebetween the first wheel 151 and the second wheel 152, and also less thanthe distance between the balls 153, accurate knowledge of the past andpresent positions of the mobile apparatus 140 as well as the printedlocation of the functional device can allow the controller 170 to selectpaths of motion of the mobile apparatus 140 that do not include runningover the printed functional device.

The invention present has been described in detail with particularreference to certain preferred embodiments thereof, but it will beunderstood that variations and modifications can be effected within thescope of the invention.

PARTS LIST

-   110 Position detection region-   115 Sheet of medium-   117 Plane of motion-   140 Mobile apparatus-   141 First edge-   142 Second edge-   143 Chassis-   145 First rotational direction (forward)-   150 Transport mechanism-   151 First wheel-   152 Second wheel-   153 Ball (or caster)-   154 Hub-   155 Motor-   156 Shaft-   157 Rotary encoder (for wheels)-   158 Radial line(s)-   159 Detectable reference position-   167 Motor gear-   168 Wheel gears-   170 Controller-   175 Power source-   180 Operating device-   182 Printhead-   184 Printhead die-   186 Array of nozzles-   190 Photosensor array-   200 Position-referenced mobile system-   210 Position referencing structure-   217 Detection plane-   221 First reflective cylindrical surface-   222 Second reflective cylindrical surface-   223 Third reflective cylindrical surface-   224 Axis (of first reflective cylindrical surface)-   225 Axis (of second reflective cylindrical surface)-   226 First cylinder-   227 Second cylinder-   228 Alignment features-   229 Axis (of third reflective cylindrical surface)-   230 Linear reference member-   231 First end (of linear reference member)-   232 Second end (of linear reference member)-   233 Reference marking(s)-   234 First reference marking-   235 Second reference marking-   236 Shading gradient-   237 Second linear reference member-   238 First end (of second linear reference member)-   239 Second end (of second linear reference member)-   242 First axis-   244 Second axis-   245 Third Axis-   250 Turret-   251 Rotational axis (of turret)-   252 Rotational direction (of turret)-   254 Shaft (of turret motor)-   255 Turret motor-   256 Shaft (of turret)-   257 Rotary encoder (for turret)-   258 Gear-   259 Gear-   260 Position detection assembly-   261 First photo detector-   262 First hollow tube-   263 Second photo detector-   264 Second hollow tube-   265 Laser-   266 Cylindrical package-   267 Incident beam-   268 First reflected beam-   269 Second reflected beam-   271 Signal amplitude (from first photo detector)-   272 Signal amplitude (from second photo detector)-   273 Peak (of signal amplitude from first photo detector)-   274 Peak (of signal amplitude from second photo detector)-   275 First direction-   276 Predetermined threshold-   281 First vector-   282 Second vector-   283 Third vector-   285 Linear reference member-   286 Curved surface-   287 Axis (of curved surface)-   288 Reflected beam-   291 Third photo detector-   293 Fourth photo detector-   295 Second laser-   297 Second incident beam-   298 Third reflected beam-   299 Fourth reflected beam-   D1, D2 Predetermined distance-   P Position-   H Heading-   s Spacing-   α,β,γ Angle

1. A position-referenced mobile system comprising: a mobile apparatusincluding: a transport mechanism for moving the mobile apparatus alongor substantially along a plane of motion; a rotatable position detectionassembly including: a laser; a first photo detector; and a second photodetector; and at least one encoder for monitoring an amount of rotationof the position detection assembly; a controller for interpretingsignals provided by the first photo detector and the second photodetector; and a position referencing structure including: a reflectivelinear reference member; a first reflective cylindrical surface disposedat a first end of the linear reference member; and a second reflectivecylindrical surface disposed at a second end of the linear referencemember.
 2. The position-referenced mobile system of claim 1, wherein anaxis of the first reflective cylindrical surface is disposed at apredetermined distance from an axis of the second reflective cylindricalsurface.
 3. The position-referenced mobile system of claim 1, whereinthe first reflective cylindrical surface is part of a first cylinder,the second reflective cylindrical surface is part of a second cylinder,and the first and second cylinder are positioned respectively at thefirst end and second end of the linear reference member.
 4. Theposition-referenced mobile system of claim 3, wherein the first andsecond ends of the linear reference member include alignment featuresfor positioning the first and second cylinders respectively.
 5. Theposition-referenced mobile system of claim 1, wherein the rotatableposition detection assembly further includes: a turret having arotational axis that is perpendicular to or substantially perpendicularto the plane of motion of the mobile apparatus; and a turret motor forrotating the turret about its rotational axis.
 6. Theposition-referenced mobile system of claim 5, wherein the at least oneencoder for monitoring an amount of rotation of the position detectionassembly is mounted on a shaft of the turret.
 7. The position-referencedmobile system of claim 6, wherein the at least one encoder includes adetectable reference position.
 8. The position-referenced mobile systemof claim 1, wherein the first photo detector is disposed within a firsthollow tube, and the second photo detector is disposed within a secondhollow tube.
 9. The position-referenced mobile system of claim 8,wherein the first hollow tube, the second hollow tube and the laser areparallel to or substantially parallel to each other.
 10. Theposition-referenced mobile system of claim 9, wherein axes of the firsthollow tube, the second hollow tube and the laser are disposed in atriangular relative relationship to each other.
 11. Theposition-referenced mobile system of claim 9, wherein a first axis ofthe first hollow tube and a second axis of the second hollow tube aredisposed within a detection plane that is parallel to or substantiallyparallel to the plane of motion, and wherein an axis of the laser isdisposed between the first axis and the second axis.
 12. Theposition-referenced mobile system of claim 10, wherein the axis of thelaser is displaced from the detection plane.
 13. The position-referencedmobile system of claim 1, wherein an axis of the first reflectivecylindrical surface and an axis of the second reflective cylindricalsurface are perpendicular or substantially perpendicular to the plane ofmotion.
 14. The position-referenced mobile system of claim 1, whereinthe linear reference member includes a curved surface having an axisthat is parallel or substantially parallel to the plane of motion. 15.The position-referenced mobile system of claim 1, wherein the linearreference member includes a plurality of reference markings.
 16. Theposition-referenced mobile system of claim 15, wherein the plurality ofreference markings are spaced apart by a spacing that is larger than awidth of a beam of the laser.
 17. The position-referenced mobile systemof claim 15, wherein a first reference marking of the plurality ofreference markings has a different width than a width of a secondreference marking of the plurality of reference markings.
 18. Theposition-referenced mobile system of claim 15, wherein a referencemarking includes a shading gradient.
 19. The position-referenced mobilesystem of claim 1, wherein the transport mechanism includes: a firstwheel; a second wheel; a first motor for rotating the first wheel; asecond motor for rotating the second wheel; a first encoder formonitoring an amount of rotation of the first motor; and a secondencoder for monitoring an amount of rotation of the second motor. 20.The position-referenced mobile system of claim 19, wherein thecontroller is configured to provide instructions to the first motor andthe second motor.
 21. The position-referenced mobile system of claim 20,wherein the first motor and the second motor are configured to drive thefirst wheel and the second wheel independently of each other in either aforward direction or a reverse direction.
 22. The position-referencedmobile system of claim 1, wherein the reflective linear reference memberis a first linear reference member and the positioning referencestructure further includes: a second reflective linear reference memberdisposed proximate the first cylindrical surface and alignedperpendicular or substantially perpendicular to the first linearreference member; and a third reflective cylindrical surface disposed atan end of the second reflective linear reference member that is oppositethe end to which the first cylindrical surface is proximate.
 23. Theposition-referenced mobile system of claim 22, wherein an axis of thefirst cylindrical surface is disposed at a predetermined distance froman axis of the third cylindrical surface.
 24. The position-referencedmobile system of claim 22, wherein the first linear reference member andthe second linear reference member each include a plurality of referencemarkings.
 25. The position-referenced mobile system of claim 22, thelaser being a first laser, wherein the rotatable position detectionassembly further includes: a second laser; a third photo detector; and afourth photo detector.
 26. The position-referenced mobile system ofclaim 25, wherein the first laser and the second laser are orientedperpendicular or substantially perpendicular to each other.
 27. Theposition-referenced mobile system of claim 1, wherein the mobileapparatus includes a device for performing an operation directed by thecontroller as a function of a detected position of the mobile apparatus.28. The position-referenced mobile system of claim 27, wherein thedevice is a marking device.
 29. The position-referenced mobile system ofclaim 28, wherein the device includes an array of nozzles for ejectingdrops of liquid.
 30. The position-referenced mobile system of claim 27,wherein the device is a cutting device.
 31. The position-referencedmobile system of claim 27, wherein the device is configured to performthe operation on a medium with which the first wheel and the secondwheel are in contact.
 32. The position-referenced mobile system of claim1, wherein the mobile apparatus further includes a power source.
 33. Theposition-referenced mobile system of claim 1, wherein the controller ismounted on the mobile apparatus.